Insulated panel and glazing system comprising the same

ABSTRACT

The invention provides a translucent glazing panel comprising: (a) a thermoplastic panel comprising (i) an outer wall having an inner surface defining an internal channel, the internal channel having an internal volume, and (ii) at least one inner wall protruding from the inner surface into the internal channel, and (b) hydrophobic aerogel particles, the hydrophobic aerogel particles being disposed within the channel. The invention also provides an insulated glazing system comprising: (a) a first U-shaped element, (b) a second U-shaped element, the first and second elements being disposed to define a cavity therebetween, and (c) an insulating panel disposed within the cavity. The insulated glazing system can further comprise hydrophobic aerogel particles disposed within the internal channel of the insulating panel. The insulating panel of the glazing system also can be the same as the translucent glazing panel described herein.

FIELD OF THE INVENTION

This invention pertains to insulated panels and glazing systemscomprising the same.

BACKGROUND OF THE INVENTION

In an effort to improve indoor lighting conditions and the aestheticappeal of enclosed spaces, architects and builders have begun toconstruct buildings using an increasing large amount of glazingmaterials and systems, such as windows, skylights, and transparent ortranslucent walls and roofs. While the use of such glazing materials candramatically improve the quality of indoor lighting, buildingsincorporating relatively large amounts of such glazing materials oftenare poorly insulated. More specifically, the thermal transmission ofconventional glazing materials typically is significantly higher thanthe thermal transmission of conventional building materials orstructures, such as framed roofs and walls. Therefore, the overallthermal transmission of a building incorporating relatively largeamounts of such glazing materials typically is significantly higher thana similar structure using less of the same, and such buildings oftenexperience relatively large amounts of heat flux across the glazingmaterials, which can dramatically increase the cost of maintaining theclimate within the building at a level considered comfortable by theoccupants. Accordingly, several attempts have been made to address therelatively poor (i.e., high) thermal transmission of conventionalglazing materials and systems.

For example, glazing materials and systems, such as windows, have beendeveloped which incorporate an air space between two vitreous (e.g.,glass) or thermoplastic surfaces. One such popular glazing material iscommonly referred to as a “multiwall panel.” These multiwall panelstypically comprise two thermoplastic sheets and a plurality ofsupporting members disposed between the thermoplastic sheets. Thethermoplastic sheets and the supporting members together define aplurality of chambers disposed between the thermoplastic sheets and thesupporting members. Insofar as gases have lower thermal conductivitiesthan solid materials, such as glass and thermoplastics, the gases withinthe chamber provide an insulating layer that serves to decrease and/orretard thermal transmission across the panel. While such multiwallpanels do exhibit improved (i.e., lower) thermal transmission thanconventional, single-pane glazing materials, condensation often formswithin the chambers as the panels are exposed to differences intemperature and/or humidity across the major surfaces of the panel. Thehumid environment provided by such condensation can promote the growthof mold and mildew within the chambers of the panel. Furthermore, thestructure of the multiwall panels often causes the panel to unevenlyrefract visible light, which can negatively impact the indoor lightingquality of a structure incorporating the panels as a glazing material.

Another glazing system that has been developed to provide an improved(i.e., lower) thermal transmission relative to conventional glazingmaterials and systems is commonly referred to as double-glazed U-profileor U-channel glass. These glazing systems typically comprise a pair ofU-shaped glass elements disposed in such a way as to form a chamberbetween the two elements. While the gases contained within this channelcan retard thermal transmission across the glazing system (i.e., betweenthe two glass elements), the glazing system typically further comprisesan insulating material disposed within the chamber formed between thetwo elements. The most commonly used insulating material is a rigidpanel which consists of a plurality of acrylic (e.g., poly(methylmethacrylate)) capillaries covered by two glass fiber mats. Theindividual acrylic capillaries are arranged in a substantially paralleldirection so that the panel resembles a honeycomb structure, the ends ofwhich are covered by the glass fiber mats. These rigid insulation panelscan often dramatically improve (i.e., lower) the thermal transmission ofa glazing system incorporating the same.

However, the costs saved due to the improved thermal transmission of theglazing system can often be partially offset by the relatively highlabor costs associated with the installation of such insulating panels.For instance, the insulating panels are extremely fragile and frequentlybreak during the installation due to their relatively large dimensions(e.g., up to about 6 meters or more in length). The debris generated bysuch breakage (e.g.,. glass fibers) can create an environmental hazardfor the workers installing the insulating panels and must bepainstakingly removed. Furthermore, the insulating panels typically areadhered to one of the glass elements (e.g., the glass element facing theoutside of the building) before the other glass element is installed. Insuch a configuration, the insulating panel impedes the drainage ofcondensation that forms on the glass element to which the panel isadhered. As noted above, the humid environment provided by suchcondensation can then promote the growth of mold and mildew within thechamber formed by the glass elements.

A need therefore exits for an insulated panel that is suitable for useas a glazing material and a glazing system comprising such an insulatedpanel, both of which address the foregoing and other problems associatedwith existing insulated glazing materials and systems. The inventionprovides such an insulated panel and glazing system. These and otheradvantages of the invention, as well as additional inventive features,will be apparent from the description of the invention provided herein.

BRIEF SUMMARY OF THE INVENTION

The invention provides a glazing panel, preferably translucent,comprising: (a) a thermoplastic panel comprising (i) an outer wallhaving an inner surface defining an internal channel, the internalchannel having an internal volume, and (ii) at least one inner wallprotruding from the inner surface into the internal channel, and (b)hydrophobic aerogel particles, the hydrophobic aerogel particles beingdisposed within the channel.

The invention further provides a glazing panel, preferably translucent,comprising: (a) a thermoplastic panel comprising (i) a firstthermoplastic sheet, (ii) a second thermoplastic sheet, and (iii) two ormore supporting members, the supporting members being disposed betweenthe first and second thermoplastic sheets, and the supporting membersdefining at least one channel disposed between the first and secondthermoplastic sheets, the channel having an internal volume, and (b)hydrophobic aerogel particles, the hydrophobic aerogel particles beingdisposed within the channel.

The invention also provides an insulated glazing system comprising: (a)a first element, preferably a U-shaped glass element comprising a basefrom which at least two legs extend, (b) a second element, preferably aU-shaped glass element comprising a base from which at least two legsextend, the first and second elements being disposed to define a cavitytherebetween, (c) an insulating panel disposed within the cavity, theinsulating panel comprising an outer wall defining an internal channel,the internal channel having an internal volume, and (d) hydrophobicaerogel particles, the hydrophobic aerogel particles being disposedwithin the internal channel.

The invention additionally provides an insulated glazing systemcomprising: (a) a first element, preferably a U-shaped glass elementcomprising a base from which at least two legs extend, (b) a secondelement, preferably a U-shaped glass element comprising a base fromwhich at least two legs extend, the first and second elements beingdisposed to define a cavity therebetween, and (c) an insulating paneldisposed within the cavity, the insulating panel comprising (i) an outerwall having an inner surface defining an internal channel, the internalchannel having an internal volume, and (ii) at least one inner wallprotruding from the inner surface into the internal channel, the outerwall and inner wall being unitarily formed of a thermoplastic resin.

The invention provides an insulated glazing system comprising: (a) afirst element, preferably a U-shaped glass element comprising a basefrom which at least two legs extend, (b) a second element, preferably aU-shaped glass element comprising a base from which at least two legsextend, the first and second elements being disposed to define a cavitytherebetween, and (c) an insulating panel disposed within the cavity,the insulating panel comprising (i) a first thermoplastic sheet, (ii) asecond thermoplastic sheet, the first and second thermoplastic sheetsbeing substantially parallel to each other, and (iii) at least twosupporting members, the supporting members being disposed between thefirst and second thermoplastic sheets, and the supporting membersdefining at least one channel disposed between the first and secondthermoplastic sheets.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective sectional view of an insulating panel accordingto teachings of the invention comprising an outer wall defining aninternal channel and at least one inner wall protruding into the innerchannel.

FIG. 2 is a perspective sectional view of another insulating panelaccording to teachings of the invention comprising an outer walldefining an internal channel and a plurality of inner walls protrudinginto the inner channel from opposing portions of the inner surface ofthe outer wall.

FIG. 3 is a perspective sectional view of an insulating panel accordingto teachings of the invention comprising an outer wall defining aninternal channel and at least one inner wall protruding into theinternal channel and contacting the inner surface of the outer wall atat least two distinct points.

FIG. 4 is a perspective sectional view of an insulating panel accordingto teachings of the invention comprising a first thermoplastic sheet, asecond thermoplastic sheet, and two or more supporting members disposedbetween the first and second thermoplastic sheets to define at least onechannel disposed between the first and second thermoplastic sheets.

FIG. 5 is a perspective sectional view of an insulating panel similar tothe panel depicted in FIG. 4 in which a third thermoplastic sheet isdisposed between the first and second thermoplastic sheets.

FIG. 6 is a perspective sectional view of an insulating panel similar tothe panel depicted in FIG. 5 in which substantially all of the internalvolume of the channels is filled with hydrophobic aerogel particles.

FIG. 7 is a perspective sectional view of an insulated glazing systemaccording to teachings of the invention comprising a first U-shapedelement, a second U-shaped element, and an insulating panel disposedwithin the cavity formed by the elements.

FIG. 8 is a perspective sectional view of an insulated glazing systemsimilar to the system depicted in FIG. 7 in which the insulating panelfurther comprises at least one inner wall protruding into the internalchannel of the insulating panel.

FIG. 9 is a perspective sectional view of an insulated glazing systemsimilar to the system depicted in FIG. 8 in which at least one of theinner walls intersect the inner surface of the outer wall at at leasttwo distinct points.

FIG. 10 is a perspective sectional view of an insulated glazing systemaccording to teachings of the invention comprising a first element, asecond element, and an insulating panel disposed within the cavityformed by the elements, the insulating panel comprising a firstthermoplastic sheet, a second thermoplastic sheet, and at least twosupporting members disposed between the first and second thermoplasticsheets to define at least one channel disposed between the first andsecond thermoplastic sheets.

FIG. 11 is a perspective sectional view of an insulated glazing systemsimilar to the system depicted in FIG. 10 in which the insulating panelfurther comprises a third thermoplastic sheet disposed between the firstand second thermoplastic sheets.

FIG. 12 is a perspective sectional view of an insulated glazing systemsimilar to the system depicted in FIG. 10 in which the glazing systemfurther comprises a sealant disposed between the elements.

FIG. 13 is a perspective sectional view of an insulated glazing systemsimilar to the system depicted in FIG. 10 in which a sealant is attachedto the perimeter of the insulating panel.

FIG. 14 is a perspective sectional view of an insulated glazing systemsimilar to the system depicted in FIG. 10 in which the sealant isattached to the perimeter of the insulating panel, and the sealant alsois disposed between the elements.

FIG. 15 is a sectional view of a modular insulated glazing systemcomprising an insulated glazing system similar to that depicted in FIG.14.

DETAILED DESCRIPTION OF THE INVENTION

Turning now to the drawings, there is shown in FIG. 1, a glazing panel100 constructed in accordance with teachings of the invention. Theglazing panel 100 has a length and comprises an outer wall 102 having aninner surface 104. The outer wall 102 defines an internal channel 106.

In accordance with the invention, and in order to maximize theinsulating, light-transmitting, and moisture-resistant properties of theglazing panel, the panel 100 is preferably transparent or translucentand comprises hydrophobic aerogel particles 110 disposed within theinternal channel. For the purposes of this disclosure, the termtranslucent will be used to describe both transparent and translucentmaterials and structures. While not wishing to be bound to anyparticular theory, it is believed that the relatively large internalvolume of the hydrophobic aerogel particles provides an insulating layerin the glazing panel, thereby decreasing the thermal transmission (i.e.,U-value) of a glazing panel according to the invention. Furthermore, itis believed that the aggregate light scattering properties of acollection of the hydrophobic aerogel particles (e.g., the particlecontained within the channel or any part thereof) contributes to thediffusion of visible light transmitted through the panel, therebyimproving the quality of transmitted light that passes through the paneland improving the internal lighting of any structure utilizing the sameas a glazing material (e.g., a window, skylight, or structural glazingelement). Lastly, it is believed that the hydrophobic nature of thehydrophobic areogel particles prevents, at least in part, the formationof condensation on the internal surfaces of a translucent glazing panelaccording to the invention as the glazing panel is exposed todifferences in temperature and/or humidity across the major surfaces ofthe glazing panel (e.g., across the interior surface and exteriorsurface of a window incorporating a translucent glazing panel accordingto the invention).

The hydrophobic aerogel particles contained in a glazing panel accordingto the invention can be any suitable hydrophobic aerogel particles. Thehydrophobic aerogel particles can comprise organic aerogel particles,inorganic aerogel particles (e.g., metal oxide aerogel particles), or amixture thereof. When the hydrophobic aerogel particles comprise organicaerogel particles, the organic aerogel particles preferably are selectedfrom the group consisting of resorcinol-formaldehyde aerogel particles,melamine-formaldehyde aerogel particles, and combinations thereof. Whenthe hydrophobic aerogel particles comprise inorganic aerogel particles,the inorganic aerogel particles preferably are metal oxide aerogelparticles selected from the group consisting of silica aerogelparticles, titania aerogel particles, alumina aerogel particles, andcombinations thereof. Most preferably, the hydrophobic aerogel particlesare silica aerogel particles.

In order to further control placement and distribution of the aerogelparticles within the internal channel 106, the panel 100 preferablyfurther includes one or more inner walls 108, as shown in FIG. 1. Theinner wall 108 protrudes into the internal channel 106 from the innersurface 104 of the outer wall 102 to at least partially divide theinternal channel 106. In this way, the aerogel particles 110 aredisposed within and fill at least a portion of the internal channel 106formed by the outer wall 102. In the currently preferred embodiment,substantially all of the internal volume of the internal channel 106 isfilled with hydrophobic aerogel particles 110.

Preferably, the panel 100 comprises a plurality of inner walls 108(e.g., two or more internal walls) protruding from the inner surface 104of the outer wall 102. When the translucent glazing panel 100 comprisesa plurality of inner walls 108, the inner walls 108 can be provided inany suitable configuration. For example, in FIG. 1, the inner walls 108are disposed adjacent one another, protruding from a single section ofthe inner wall 108. Conversely, in FIG. 2, a plurality of inner walls208 protrude from opposing portions of the inner surface 204 of theouter wall 202. (As a general matter, similar reference numerals will beutilized in the various illustrated embodiments of the invention.)

In order to further control the distribution of the aerogel particles110 within the internal channel 106, 206, the volume of the internalchannel 106, 206 may be further divided into a plurality of channels. Asshown in FIG. 3, the inner wall 308 a of the panel 300 can intersect theinner surface 304 of the outer wall 302 at at least two distinct points.The panel 300 can include one such wall 308 a, as shown in FIG. 3, sothat the outer wall 302 and inner wall 308 a define two internalchannels 306, 310 having internal volumes. It will be appreciated bythose of skill in the art that the inner wall 308 a may extendsubstantially the entire length of the panel 300 or extend only aportion of the length. Thus, where the inner wall 308 a extends along atleast a portion of the length, the outer wall 302 and inner wall 308 adefine first and second internal channels 306, 310. Further, the innerwall 308 a may have any cross-sectional configuration. For example, itmay be curved, or it may include an angular portion, or it may be formedfrom, in essence, the engagement of two inner walls (such as 308) thatintersect the inner surface 304 at only one point. The inner walls mayalso intersect the inner surface 304 at three or more points.

The panel 300 may likewise include one or more inner walls 308 thatprotrude from the inner surface 304 of the outer wall 302, but do notintersect the inner surface 304 of the outer wall 302 at at least twodistinct points, such as walls 108 and 208 in FIGS. 1 and 2. Hydrophobicaerogel particles 312 are disposed within at least one of the internalchannels 306, 310, preferably, filling at least a portion of theinternal volume of both of the internal channels 306, 310. In acurrently preferred embodiment, substantially all of the internal volumeof the internal channels 306, 310 is filled with hydrophobic aerogelparticles 312. While the inner wall 308 a prevents or inhibits movementof the particles 312 between the channels 306, 310, the inner walls 308further control the location of the aerogel particles 312, but do notnecessarily prevent particle 312 movement within a given channel 306,310 in and of themselves.

It will thus be appreciated by those of skill in the art, that theinternal configuration of the panel 300 may include a plurality of suchinner walls 308 a that intersect the inner surface 304 to create aplurality of such channels 306, 310, with or without such inner walls308 that intersect the inner surface 304 at only one position. Forexample, the panel 400, 500 may include a plurality of inner walls 406,506, 512 that intersect the internal surface of the outer wall at two ormore points, as shown in FIGS. 4 and 5, respectively.

More specifically, as depicted in FIG. 4, for example, the translucentglazing panel comprises a first thermoplastic sheet 402, a secondthermoplastic sheet 404, and two or more supporting members 406 disposedbetween the first and second thermoplastic sheets 402, 404. The firstthermoplastic sheet 402 preferably is substantially parallel to thesecond thermoplastic sheet 404. The supporting members 406 define atleast one channel 408 disposed between the first and secondthermoplastic sheets 402, 404. As with the other embodiments, theglazing panel further comprises hydrophobic aerogel particles 410disposed within at least one, and preferably at least a portion of orall, of the channels 408 defined by the supporting members 406.

As depicted in FIG. 5, the thermoplastic panel 500 can further comprisea third thermoplastic sheet 512 disposed between the first thermoplasticsheet 502 and the second thermoplastic sheet 504, the thirdthermoplastic sheet 512 and the supporting members 506 defining at leasttwo rows of channels 508 disposed between the first and secondthermoplastic sheets 502, 504. As shown in FIG. 5, preferably, the thirdthermoplastic sheet 512 is substantially parallel to the first andsecond thermoplastic sheets 502, 504. The hydrophobic aerogel particles510 are disposed within at least one, and preferably a portion of orall, of the channels 508 formed by the third thermoplastic sheet 512 andthe supporting members 506. Most preferably, as depicted in FIG. 6,substantially all of the internal volume of each of the channels 508defined by the first, second, and third thermoplastic sheets 502, 504,512 and the supporting members 506 are filled with hydrophobic aerogelparticles 510.

The outer wall and inner wall(s) of the glazing panel can be formedusing any suitable method, with any suitable material. Referring to FIG.1, for example, the outer wall 102 and inner walls 108 can be unitarilyformed of a thermoplastic resin using thermoplastic molding methodsknown in the art (e.g., injection molding, extrusion molding, etc.).Alternatively, the glazing panel can include separately formedcomponents that are later assembled. For example, the outer wall 102 cancomprise, for example, a first thermoplastic sheet 112, a secondthermoplastic sheet 114, and at least two supporting members 116disposed between the first and second thermoplastic sheets 112, 114 toform the outer wall 102. In such an embodiment, the first thermoplasticsheet 112, second thermoplastic sheet 114, supporting members 116, andinternal walls 108 may be joined using an adhesive, sonic welding, orany other method suitable for joining two or more articles comprisingthe material of the walls.

Similar fabrication methods may be utilized with the other embodiments.For example, in the embodiment of FIG. 4, the entire panel 400 may beinjection molded or extruded. Alternately, the first thermoplastic sheet402, second thermoplastic sheet 404, and supporting members 406 of theglazing panel 400 can be formed using any suitable method, and thenjoined using an adhesive, sonic welding, or any other method suitablefor joining two or more articles comprising the material of the walls.

A thermoplastic panel preferably comprises any suitable thermoplasticresin. Suitable thermoplastic resins preferably exhibit a relativelyhigh mechanical strength and can withstand large temperature gradients.The thermoplastic of the panel preferably comprises a thermoplasticresin selected from the group consisting of polycarbonate, polyethylene,poly(methyl methacrylate), poly(vinyl chloride), and mixtures thereof.Most preferably, the thermoplastic of the panel comprises polycarbonate.

The glazing panel of the invention can be provided in any suitable sizeand/or shape. Typically, the glazing panel can be used to replace thevitreous glazing material (e.g., glass) used in conventional glazingsystems (e.g., windows, skylights, etc.). Accordingly, a glazing panelaccording to the invention generally has a thickness of less than about100 mm. When the glazing panel comprises an outer wall and at least oneinner wall protruding from the surface thereof, as depicted in FIG. 1,the opposing surfaces of the outer wall 102 forming the thickness of theglazing panel 100 typically are separated by less than about 100 mm,preferably less than about 50 mm, and more preferably less than about 30mm. Alternatively, when the glazing panel comprises a firstthermoplastic sheet and a second thermoplastic sheet, as depicted inFIG. 4, for example, the first thermoplastic sheet 402 and the secondthermoplastic sheet 404 typically are separated by less than about 1 cm,preferably less than about 50 mm, and more preferably less than about 30mm.

The quality of visible light transmitted through a glazing panelaccording to the invention preferably is more diffuse than the visiblelight transmitted through similar glazing panels that are not filledwith hydrophobic aerogel particles. In particular, a glazing panelaccording to the invention preferably exhibits an improved haze value(e.g., a higher haze value) than a similar glazing panel that is notfilled with hydrophobic aerogel particles. The haze value is ameasurement of light-transmitting and wide-angle-light-scatteringproperties of planar sections of materials, such as glazing materials(e.g., transparent or translucent plastics). The haze value is definedin ASTM Standard D1003, entitled “Standard Test Method for Haze andLuminous Transmittance of Transparent Plastics,” and can be measured inaccordance with the procedures set forth therein. As utilized herein,the term “haze value” refers to the haze value of a glazing panel asdefined and measured in accordance with ASTM Standard D1003. Preferably,a thermoplastic glazing panel according to the invention has a hazevalue of about 50% or more, more preferably about 75% or more.

In accordance with another aspect of the invention, the inventiveglazing panels, as shown for example in FIGS. 1-6, may be incorporatedinto a so-called U-channel glass glazing system or other appropriateglazing system. Turning now to FIG. 7, the insulated glazing system 700comprises elements 702, 708 that define a cavity 714 there between. Inthe illustrated embodiment, a pair of elongated, U-shaped glass elements702, 708 are provided; The first U-shaped glass element 702 comprises abase 704 from which at least two legs 706 extend, and the secondU-shaped element 708 comprises a base 710 from which at least two legs712 extend. It will be appreciated that the elements 702, 708 could havean alternately structure. For example, they could each have an“L-shaped” structure, or one could have a “U-shaped” structure and theother an elongated flat structure which covers the internal channel ofthe U-shaped structure to form an elongated cavity therebetween. Thus,the invention is not limited to the inclusion of such U-shaped glasselements and the following explanation of structures utilizing suchU-shaped glass elements is equally applicable to elongated elements ofan alternate shape or cross-section.

In assembly, the first and second glass elements 702, 708 are disposedto define a cavity 714 therebetween. While the legs 706, 712 of theU-shaped glass elements 702, 708 are disposed in a staggered arrangementin the embodiment of FIG. 7, it will be appreciated that the first andsecond glass elements 702, 704 can be arranged in any suitable manner todefine the cavity. For example, the legs of the first glass element canbe disposed adjacent to the base of the second glass element, therebydefining a cavity bounded by the base and legs of the first glasselement and the base of the second glass element. Alternatively, theends of the legs of the first and second glass elements can be disposedadjacent to each other, thereby defining a cavity bounded by the baseand legs of the first and second glass elements. The alternate possiblecross-sectional shaped glass element structures may be similarlydisposed in various manners to define the cavity.

The glazing system 700 according to teachings of the invention furthercomprises an insulating panel 716 disposed within the cavity 714 formedby the first and second glass elements 702, 708. The insulating panel ofa glazing system according to the invention can have any suitabledimension. As disclosed above, the insulating panel 716 comprises anouter wall 718 defining an internal channel 720 that preferablycomprises hydrophobic aerogel particles 722. Typically, at least aportion, and preferably substantially all, of the internal volume of theinternal channel 720 is filled with hydrophobic aerogel particles 722.The structure of the insulating panel itself may be of any appropriatedesign. By way of example only, the structure of the insulating panel100 of FIG. 1 may be included in the glazing system 800, as shown inFIG. 8; the insulating panel 400 of FIG. 4 may be included in theglazing system 1000 of FIG. 10; or the insulating panel 500 of FIG. 5may be included in the glazing system 1100 of FIG. 11. It will beappreciated, however, that the insulating panel 916 may have analternate design, such as is disclosed, for example in FIG. 9.

Turning now to FIG. 12, in assembly, the first and second glass elements1202, 1208 are disposed to form the cavity 1214 therebetween. The firstand second glass elements 1202, 1208 of this embodiment are U-shaped andinclude legs 1206, 1212 extending from bases 1204, 1210, respectively.In order to reduce thermal transmission between the first and secondglass elements 1202, 1208, an insulated glazing system according to theinvention preferably comprises at least one sealant 1228 disposedbetween at least a portion of adjacent sections of the first and secondglass elements 1202, 1208. As depicted in FIG. 12, the sealant 1228typically is disposed to surround the distal tips 1206 a, 1212 a of theinternally disposed legs 1206, 1212 of first and second U-shaped glasselements 1202, 1208. In this way, the sealant 1228 provides a seal notonly between adjacently disposed legs, 1206, 1212, but also between thedistal tips 1206 a, 1212 a of the internally disposed legs 1206, 1212and the bases 1206, 1212. It will be appreciated, however, that thesealant 1228 can be alternately disposed.

Furthermore, in order to minimize or prevent thermal conduction betweenthe insulating panel and the first and second glass elements, a sealantcan be attached to at least a portion of the perimeter of the insulatingpanel. As depicted in FIG. 13, the sealant 1328 can be attached to theperimeter of the insulating panel 400, thereby separating and isolatingthe insulating panel 400 from the adjacent legs 1306, 1312 of the firstand second glass elements. 1302, 1308.

Alternatively, the sealant can be attached to the perimeter of theinsulating panel in such a way as to separate and isolate the insulatingpanel from the bases of the first and second glass elements. Preferably,at least a portion of the sealant is disposed between the insulatingpanel and at least one of the first and second glass elements. Acurrently preferred example of such an embodiment of the glazing systemof the invention is depicted in FIG. 14. In particular, the sealant 1428is disposed between the insulating panel 400 and the adjacent legs 1406,1412 of the first and second glass elements 1402, 1408. As illustrated,the sealant 1428 is further disposed between the adjacent legs 1406,1412 of the first and second glass elements 1402, 1408, as well asbetween the adjacent portions of one of the legs 1406, 1412 of the glasselements and the base 1404, 1410 of the other glass element. It will beappreciated by those of skill in the art that the insulating panel ispreferably spaced away from the inside surfaces of the glass elements asshown in FIGS. 7-14. In this way, should any condensation from on aninside surface of either or both of the glass elements or on the outsidesurface of the insulating panel, the condensation can run down thesurface, rather than collecting between the same.

The sealant can comprise any suitable material. Suitable sealantsinclude, but are not limited to, silicone (e.g., silicone caulk,silicone adhesive, silicone gaskets), polymeric sealants (e.g.,polyethylene gaskets), etc. Preferably, the sealant comprises silicone,more preferably a silicone gasket.

The insulated glazing system can be assembled in any appropriate order.For example, a first of the glass elements may be placed, the insulatingpanel disposed therebetween, and then the second of the glass elementsplaced. Alternately, the glass elements may be assembled together andthe insulating panel then inserted in the cavity between the glasselements.

An insulated glazing system according to teaching of the invention to beutilized in the construction of modular glazing systems is shown, forexample, in FIG. 15. In such a modular arrangement, individual,partially assembled modules of glass elements with an enclosedinsulating panel may be provided, the partially assembled modules ofglass elements with insulating panels may then be assembled on site toform an extended glazed structure. In particular, the modular glazingsystem 1500 comprises a first U-shaped glass element 1502 comprising abase 1504 from which at least two legs 1506 extend and a second U-shapedglass element 1508 comprising a base 1510 from which at least two legs1512 extend. The first and second glass elements 1502, 1508 are disposedto define a cavity 1514 therebetween. The glazing system 1500 furthercomprises an insulating panel 1516 disposed within the cavity 1514formed by the first and second glass elements 1502, 1508. The insulatingpanel 1516 can comprise any of the insulating panels described above forthe insulated glazing system of the invention. As depicted, theinsulating panel 1516 comprises a first thermoplastic sheet 1518, asecond thermoplastic sheet 1520, and at least two supporting members1522. The supporting members 1522 are disposed between the first andsecond thermoplastic sheets 1518, 1520 in such a way to define at leastone channel 1524 disposed between the first and second thermoplasticsheets 1518, 1520. In order to improve (i.e., lower) the thermaltransmission of the glazing system 1500, the glazing system can furthercomprise hydrophobic aerogel particles 1526 disposed within at least oneof the channels 1524 formed by the supporting members 1522. Preferably,at least a portion of the internal volume of one of the channels 1524 isfilled with hydrophobic aerogel particles 1526. More preferably,substantially all of the internal volume of at least one of the channels1524 is filled with hydrophobic aerogel particles 1526. Most preferably,at least a portion (or substantially all) of the internal volume of eachof the channels 1524 is filled with hydrophobic aerogel particles 1526.The glazing system 1500 can further comprise at least one sealant 1528disposed between the insulating panel 1516 and adjacent portions of thefirst and second glass elements 1502, 1508. In order to prevent contactbetween the glass elements, the sealant 1528 preferably is furtherdisposed between adjacent portions of the first and second glasselements (e.g., between the legs 1506, 1512 of the first or second glasselement 1502, 1508 and the base 1504 of the other glass element).

In summary, in order to minimize the thermal transmission of the glazingsystem, the insulating panel preferably is substantially coextensivewith the length and the width of the cavity defined by the first andsecond glass elements (e.g., the length and width of the insulatingpanel are substantially the same as the length and width of the cavity).More preferably, the insulating panel is coextensive with the width ofthe cavity (e.g., the difference between the width of the cavity and thewidth of the panel is limited to the amount necessary to allow the panelto be inserted into the cavity and to accommodate any sealant disposedbetween the insulating panel and the adjacent surfaces of the glasselements forming the cavity). However, as noted above, the insulatingpanel preferably does not directly contact the first or second glasselements. Contact between the insulating panel and the glass elementscan be prevented in any suitable manner, but a sealant preferably isdisposed between the insulating panel and the first or second glasselements.

The hydrophobic aerogel particles that can be contained within theinsulating panel of the glazing system can be any suitable hydrophobicaerogel particles. The hydrophobic aerogel particles can compriseorganic aerogel particles, inorganic aerogel particles (e.g., metaloxide aerogel particles), or a mixture thereof. When the hydrophobicaerogel particles comprise organic aerogel particles, the organicaerogel particles preferably are selected from the group consisting ofresorcinol-formaldehyde aerogel particles, melamine-formaldehyde aerogelparticles, and combinations thereof. When the hydrophobic aerogelparticles comprise inorganic aerogel particles, the inorganic aerogelparticles preferably are metal oxide aerogel particles selected from thegroup consisting of silica aerogel particles, titania aerogel particles,alumina aerogel particles, and combinations thereof. Most preferably,the hydrophobic aerogel particles are silica aerogel particles.

The following examples further illustrate the invention but, of course,should not be construed as in any way limiting its scope.

EXAMPLE 1

This example demonstrates the improved U value (i.e., lower thermaltransmission) exhibited by a glazing panel according to the inventionrelative to other glazing panels that do not comprise hydrophobicaerogel particles. The corrected U values for eleven similar translucentglazing panels were measured. Each of the glazing panels comprised afirst polycarbonate sheet, a second polycarbonate sheet, and a pluralityof supporting members disposed between the first and secondpolycarbonate sheets to define a plurality of channels between the firstand second polycarbonate sheets.

Glazing Panels 1A (comparative) and 1B (invention) measuredapproximately 10 mm in thickness, and Glazing Panel 1B (invention)comprised hydrophobic aerogel particles disposed within the channels ofthe panel.

Glazing Panels 1C-1E measured approximately 16 mm in thickness andfurther comprised a third polycarbonate sheet disposed between andparallel to the first and second polycarbonate sheets, thereby formingtwo rows of channels disposed between the first and second polycarbonatesheets. Glazing Panel 1C (comparative) did not contain hydrophobicaerogel particles. Glazing Panel 1D (invention) contained hydrophobicaerogel particles disposed within both rows of channels disposed betweenthe first and second polycarbonate sheets, and Glazing Panel 1E(invention) contained hydrophobic aerogel particles disposed within onlyone row of channels disposed between the first and second polycarbonatesheets.

Glazing Panels 1F-1H measured approximately 20 mm in thickness andfurther comprised a third polycarbonate sheet disposed between andparallel to the first and second polycarbonate sheets, thereby formingtwo rows of channels disposed between the first and second polycarbonatesheets. Glazing Panel 1F (comparative) did not contain hydrophobicaerogel particles. Glazing Panel 1G (invention) contained hydrophobicaerogel particles disposed within both rows of channels disposed betweenthe first and second polycarbonate sheets, and Glazing Panel 1H(invention) contained hydrophobic aerogel particles disposed within onlyone row of channels disposed between the first and second polycarbonatesheets.

Glazing Panels 1I-1K measured approximately 25 mm in thickness andfurther comprised a third polycarbonate sheet disposed between andparallel to the first and second polycarbonate sheets, thereby formingtwo rows of channels disposed between the first and second polycarbonatesheets. Glazing Panel 1I (comparative) did not contain hydrophobicaerogel particles. Glazing Panel 1J (invention) contained hydrophobicaerogel particles disposed within both rows of channels disposed betweenthe first and second polycarbonate sheets, and Glazing Panel 1K(invention) contained hydrophobic aerogel particles disposed within onlyone row of channels disposed between the first and second polycarbonatesheets.

The U value of each glazing system was measured in accordance with ASTMStandard C518-98, entitled “Standard Test Method for Steady-StateThermal Transmission Properties by Means of the Heat Flow MeterApparatus.” The U values obtained from these measurements were thencorrected to account for the air film thermal resistance in accordancewith the guidelines set forth in Chapter 30 of the 2001 ASHRAEFundamentals Handbook. The corrected U values for Glazing Panels 1A-1Kobtained by these measurements and corrections are set forth in Table 1below. TABLE 1 Thickness, Fill Particulars, Rows of Channels Filled, andCorrected U Values for Glazing Panels 1A-1K. Rows of Glazing ThicknessChannels Corrected U Panel (mm) Fill Filled Value (W/m²K) 1A 10 — — 3.121B 10 Hydrophobic One 1.93 Aerogel Particles 1C 16 — — 2.40 1D 16Hydrophobic Two 1.31 Aerogel Particles 1E 16 Hydrophobic One 1.70Aerogel Particles 1F 20 — — 1.89 1G 20 Hydrophobic Two 1.06 AerogelParticles 1H 20 Hydrophobic One 1.55 Aerogel Particles 1I 25 — — 1.66 1J25 Hydrophobic Two 0.89 Aerogel Particles 1K 25 Hydrophobic One 1.39Aerogel Particles

The data set forth in Table 1 demonstrates that a glazing panelaccording to the invention exhibits a lower U value (i.e., lower thermaltransmission) than a similar glazing panel that does not comprisehydrophobic aerogel particles. In particular, a glazing panel that doesnot comprise hydrophobic aerogel particles disposed within thechannel(s) exhibits a corrected U value that is at least about 20%higher than a similar glazing panel that comprises hydrophobic aerogelparticles disposed within the channel(s) or at least one row of thechannels. Indeed, Glazing Panel 1I (comparative) exhibited a corrected Uvalue that was approximately 85% greater than the corrected U value ofGlazing Panel 1J (invention).

EXAMPLE 2

This example demonstrates the improved light diffusing properties (i.e.,higher haze value) exhibited by a glazing panel according to theinvention relative to other glazing panels that do not comprisehydrophobic aerogel particles. Six similar translucent glazing panels(Glazing Panels 2A-2F) were measured to determine the haze value of eachpanel. Each of the glazing panels comprised a first polycarbonate sheet,a second polycarbonate sheet, and a plurality of supporting membersdisposed between the first and second polycarbonate sheets to define aplurality of channels between the first and second polycarbonate sheets.Glazing Panels 2A (comparative) and 2D (invention) measuredapproximately 6 mm in thickness, Glazing Panels 2B (comparative) and 2E(invention) measured approximately 10 mm in thickness, and GlazingPanels 2C (comparative) and 2F (invention) measured approximately 20 mmin thickness. The channels of Glazing Panels 2D-2F (invention) werefilled with hydrophobic aerogel particles. The channels of GlazingPanels 2A-2C (comparative) were not filled with hydrophobic aerogelparticles (i.e., the channels merely contained air).

The haze value of each glazing panel was measured using an ULTRASCAN® XEspectrophotometer (available from HunterLab Associates, Reston, Va.).The results from these measurements are set forth in Table 2 below.TABLE 2 Thickness, Fill Particulars, and Haze Values for Glazing Panels2A-2F. Haze Glazing Panel Thickness (mm) Fill Value (%) 2A (comparative)6 — 48 2B (comparative) 10 — 39 2C (comparative) 20 — 31 2D (invention)6 Hydrophobic 89 Aerogel Particles 2E (invention) 10 Hydrophobic 94Aerogel Particles 2F (invention) 20 Hydrophobic 97 Aerogel Particles

The data set forth in Table 2 demonstrates that a glazing panelaccording to the invention exhibits a higher haze value than a similarglazing panel that does not contain hydrophobic aerogel particles. Inparticular, the haze value (measured in %) for a glazing panel accordingto the invention (i.e., Glazing Panels 2D-2F) is approximately two ormore times greater than the haze value for a similar glazing panel thatdoes not contain hydrophobic aerogel particles (i.e., Glazing Panels2A-2C).

EXAMPLE 3

This example demonstrates the improved U value (i.e., lower thermaltransmission) of a glazing system according to the invention relative toother glazing systems. The U values for four similar glazing systemswere measured. Each of the four glazing systems (Glazing Systems 3A-3D)was constructed using two similar U-shaped glass elements. The glasselements comprised a base, which measured approximately 262 mm inlength, and two legs perpendicularly extending from the base, which legsmeasured approximately 60 mm in length. The glass from which eachelement was constructed was approximately 7 mm thick. In order toprevent contact between the legs of one element and the inside surfaceof the base of the other element, a polymeric gasket was placed on thedistal end of each leg. The two U-shaped glass elements were arranged sothat the legs of each glass element projected from the base of the glasselement toward the base of the other glass element, thereby defining acavity between the two glass elements.

Glazing System 3A (comparative) did not comprise an insulation materialdisposed within the cavity formed by the glass elements.

Glazing System 3B (comparative) comprised a rigid insulation materialmeasuring approximately 20 mm in thickness (Okapane® available fromOkaLux GmbH, Marktheidenfeld-Altfeld, Germany) disposed within thecavity formed by the glass elements. The Okapane® rigid insulationmaterial comprised a plurality of hollow poly(methyl methacrylate) tubesmeasuring approximately 20 mm in length and arranged in a substantiallyparallel relationship. Two glass fiber mats were adhered to the ends ofthe tubes, thereby forming a rigid insulation material in which thetubes were substantially perpendicular to the glass fiber mats.

Glazing System 3C (comparative) comprised another rigid insulationmaterial measuring approximately 50 mm in thickness (Moniflex® availablefrom Isoflex AB, Gustafs, Sweden) disposed within the cavity formed bythe glass elements. The Moniflex® rigid insulation material comprisedapproximately 10 layers of corrugated cellulose acetate films, in whichthe pleats of each film were disposed in a substantially perpendiculardirection to the pleats in the adjacent films. The individual layers ofcellulose acetate film were glued together to form the rigid insulationmaterial.

Glazing System 3D (invention) comprised a hydrophobic aerogel-filledinsulated panel measuring approximately 20 mm in thickness. Theinsulated panel comprised a first polycarbonate sheet, a secondpolycarbonate sheet, and a plurality of supporting members disposedbetween the first and second polycarbonate sheets to define a pluralityof channels between the first and second polycarbonate sheets. Thehydrophobic aerogel particles were disposed within the channels formedby the supporting members.

The U value of each glazing system was measured in accordance with ASTMStandard C518-98. The U values obtained from such measurements were notcorrected to account for air film thermal resistance. The results ofthese measurement are set forth in Table 3 below. TABLE 3 InsulationType and Thickness and U Values for Glazing Systems 3A-3D. GlazingSystem Insulation U Value (W/m²K) 3A (comparative) — 3.2 3B(comparative) 20 mm Okapane ® 1.6 3C (comparative) 50 mm Moniflex ® 1.43D (invention) 20 mm Aerogel-filled Panel 1.0

As evidenced by the data set forth in Table 3, a glazing systemaccording to the invention exhibits a U value that is significantlylower than similar glazing systems that do not comprise an insulatingpanel according to the invention. In particular, a comparison of the Uvalues for Glazing Systems 3A and 3D reveals that the U value for aglazing system that did not contain any insulation material disposedwithin the cavity formed by the glass elements (i.e., Glazing System 3A)exhibited a U value that was approximately 220% greater than the U valueof a glazing system according to the invention (i.e., Glazing System3D). A comparison of the U values for Glazing Systems 3B-3D furtherreveals that the U value for glazing systems comprising commerciallyavailable insulation materials disposed within the cavity formed by theglass elements exhibited U values that were approximately 60% (GlazingSystem 3B) and 40% (Glazing System 3C) greater that the U value of aglazing system according to the invention (i.e., Glazing System 3D).

All references, including publications, patent applications, andpatents, cited herein are hereby incorporated by reference to the sameextent as if each reference were individually and specifically indicatedto be incorporated by reference and were set forth in its entiretyherein.

The use of the terms “a” and “an” and “the” and similar referents in thecontext of describing the invention (especially in the context of thefollowing claims) are to be construed to cover both the singular and theplural, unless otherwise indicated herein or clearly contradicted bycontext. The terms “comprising,” “having,” “including,” and “containing”are to be construed as open-ended terms (i.e., meaning “including, butnot limited to,”) unless otherwise noted. Recitation of ranges of valuesherein are merely intended to serve as a shorthand method of referringindividually to each separate value falling within the range, unlessotherwise indicated herein, and each separate value is incorporated intothe specification as if it were individually recited herein. All methodsdescribed herein can be performed in any suitable order unless otherwiseindicated herein or otherwise clearly contradicted by context. The useof any and all examples, or exemplary language (e.g., “such as”)provided herein, is intended merely to better illuminate the inventionand does not pose a limitation on the scope of the invention unlessotherwise claimed. No language in the specification should be construedas indicating any non-claimed element as essential to the practice ofthe invention.

Preferred embodiments of this invention are described herein, includingthe best mode known to the inventors for carrying out the invention.Variations of those preferred embodiments may become apparent to thoseof ordinary skill in the art upon reading the foregoing description. Theinventors expect skilled artisans to employ such variations asappropriate, and the inventors intend for the invention to be practicedotherwise than as specifically described herein. Accordingly, thisinvention includes all modifications and equivalents of the subjectmatter recited in the claims appended hereto as permitted by applicablelaw. Moreover, any combination of the above-described elements in allpossible variations thereof is encompassed by the invention unlessotherwise indicated herein or otherwise clearly contradicted by context.

1-76. (canceled)
 77. A glazing panel made of a thermoplastic materialand comprising outer walls connected by one or more inner walls to forminternal channels and having at least one of the channels and at leastone wall treated to enhance at least one of thermal, insulating, andmoisture-control properties.
 78. The glazing panel of claim 77, whereinat least one of the internal channels is filled with aerogel particles.79. The glazing panel of claim 77, wherein all of the internal channelsare filled with aerogel particles.
 80. The glazing panel of claim 77,wherein a sealant is applied to at least one outer wall.
 81. The glazingpanel of claim 77, wherein at least one of the internal channels isfilled with insulation material.
 82. The glazing panel of claim 81,wherein the insulation material is applied to a single layer of internalchannels.
 83. The glazing panel of claim 81, wherein the insulationmaterial is translucent.
 84. The glazing panel of claim 81, wherein theinsulation material is inorganic aerogel particles.
 85. The glazingpanel of claim 84, wherein the inorganic aerogel particles are silicaaerogel particles.
 86. The glazing panel of claim 77, wherein the panelfurther comprises at least one material for enhancing thermalproperties.
 87. The glazing panel of claim 86, wherein the material forenhancing thermal properties is silicone.
 88. The glazing panel of claim86, wherein the material for enhancing thermal properties is a polymericsealant.
 89. The glazing panel of claim 77, wherein the thermoplasticmaterial is polycarbonate.
 90. A glazing panel made of a thermoplasticmaterial and comprising outer walls connected by an inner surface thatdefines at least one internal channel, the structure having its openends covered by either the outer walls, wherein at least one of theinternal channels and at least one wall are treated to enhance at leastone of thermal, insulating, and moisture-control properties.
 91. Theglazing panel of claim 90, wherein the internal channels have a squareor rectangular shape.
 92. The glazing panel of claim 90, wherein theinner surface enhances at least one of thermal, insulating, andmoisture-control properties.
 93. The glazing panel of claim 90, whereinat least one of the internal channels is filled with aerogel particles.94. The glazing panel of claim 90, wherein all of the internal channelsare filled with aerogel particles.
 95. The glazing panel of claim 90,wherein a sealant is applied to at least one outer wall.
 96. The glazingpanel of claim 90, wherein the glazing panel has at least one internalchannel filled with insulation material.
 97. The glazing panel of claim96, wherein the insulation material is applied to a single layer ofinternal channels.
 98. The glazing panel of claim 96, wherein theinsulation material is translucent.
 99. The glazing panel of claim 96,wherein the insulation material is inorganic aerogel particles.
 100. Theglazing panel of claim 99, wherein the inorganic aerogel particles aresilica aerogel particles.
 101. The glazing panel of claim 90, whereinthe panel further comprises at least one material for enhancing thermalproperties.
 102. The glazing panel of claim 101, wherein the materialfor enhancing thermal properties is silicone.
 103. The glazing panel ofclaim 101, wherein the material for enhancing thermal properties is apolymeric sealant.
 104. The glazing panel of claim 90, wherein thethermoplastic material is polycarbonate.